US6699085B2

US6699085B2 - Engine power output control for small watercraft

Info

Publication number: US6699085B2
Application number: US10/374,019
Authority: US
Inventors: Toshiyuki Hattori
Original assignee: Yamaha Motor Co Ltd
Current assignee: Yamaha Motor Co Ltd
Priority date: 1999-01-29
Filing date: 2003-02-25
Publication date: 2004-03-02
Anticipated expiration: 2020-01-31
Also published as: US20030129886A1

Abstract

A throttle control system eases operation of the throttle lever on a small watercraft to improve rider comfort. The small watercraft includes an internal combustion engine within an engine compartment and a steering mechanism for steering the watercraft. The steering mechanism includes a handlebar assembly. The engine includes an air induction system that supplies air to the engine and includes a throttle device configured for controlling the amount of air supplied to the engine. The control system includes a throttle operator, an operator position sensor, a controller and an actuator. The throttle operator is located on the handlebar assembly and the operator position sensor and the actuator are located within the engine compartment. The operator position sensor is configured to detect the position of the throttle operator and to communicate with the controller. The actuator is configured to adjust the throttle device in response to the controller.

Description

PRIORITY INFORMATION

This application is a continuation-in-part of U.S. patent application Ser. No. 09/494,392, filed Jan. 31, 2000, now allowed, which claims priority to Japanese Patent Application No. 11-022,650, filed Jan. 29, 1999, the entire contents of which are both hereby expressly incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to an improved mechanism for controlling the speed of a personal watercraft. More particularly, the present invention relates to an improved throttle control system for a personal watercraft.

2. Description of Related Art

Personal watercraft are a relatively small sporty-type of watercraft wherein the rider sits or stands more on top of the watercraft than in other types of watercraft. Typically, a personal watercraft is designed to be operated by a single rider or operator, although accommodations are frequently made for one or more passengers.

Personal watercrafts are typically powered by an internal combustion engine. Fuel is supplied to the engine by charge formers, which can be carburetors or fuel injectors depending upon the application. Air is supplied to the engine by an air induction system. Located within the air induction system is one or more throttle valves that regulate the amount of air delivered to the engine. Because fuel flow is typically metered in proportion to the air flow, the throttle valves, in essence, control the power output of the engine and thus the speed of the watercraft as is well known in the art.

Personal watercraft typically include a handlebar that is mounted to an upper deck of the watercraft. The operator uses the handlebar to steer the watercraft. On the handlebars, near a grip, is a throttle lever. The throttle lever is typically directly coupled to the throttle valves by one or more cables. Accordingly, the operator controls the position of the throttle valves thereby the speed the watercraft by moving the throttle lever.

The throttle valves are normally biased to an idling position by one or more return springs. Another spring biases the throttle lever back to an unactuated position that corresponds to the idle position of the throttle valves. In order to further open the throttle valves and increase the speed of the watercraft, the operator typically grasps the throttle lever with one or more of her fingers and moves the lever towards the handlebar grip. When the operator releases the throttle lever, the return springs force the throttle valves and the throttle lever back to the idling position. Therefore, in order to maintain the speed of the watercraft, the operator must hold the throttle lever at a specific position against the return force of the return springs. Furthermore, if the operator's fingers slip, the throttle lever will return quickly to the idling position causing the watercraft to decelerate suddenly.

SUMMARY OF THE INVENTION

The prior art system for controlling the position of the throttle valves in a personal watercraft has several disadvantages. For example, to maintain the speed of the watercraft, the operator must hold the throttle lever against the force of the return springs. Accordingly, the operator's fingers may become tired after holding the throttle lever only for awhile. Another problem with the prior art system is that if the operator suddenly lets go of the throttle lever the throttle valves quickly return to their idling position causing the watercraft to decelerate quickly. This sudden deceleration can cause the watercraft to suddenly slip from a planing state to a non-planing state.

Accordingly, an aspect of at least one of the inventions disclosed herein involves a personal watercraft comprising a hull and an internal combustion engine disposed within the hull. The engine includes an air induction system that supplies air to the engine and has a throttle device to regulate the amount of air supplied to the engine. A steering mechanism steers the watercraft and includes a handlebar assembly coupled to the hull for this purpose. A throttle device control system includes a throttle operator that is located on the handlebar assembly and is arranged to be controlled by a rider of the watercraft. An operator position sensor is configured to detect the position of the throttle operator and to output a data signal that is indicative of the detected position of the throttle operator. A controller communicates with the operator position sensor to receive the data signal and is configured to output a control signal in response to the data signal. An actuator communicates with the controller. The actuator also is coupled to the throttle device and is adapted to adjust the throttle device in response to the control signal from the controller.

Another aspect of at least one of the inventions disclosed herein involves a personal watercraft comprising a hull and an internal combustion engine disposed within the hull. The engine includes an air induction system that supplies air to the engine and has a throttle device to regulate the amount of air supplied to the engine. A steering mechanism controls the steering movement of the watercraft and includes a handlebar assembly coupled to the hull. A throttle device control system includes a throttle operator that is located on the handlebar assembly and is arranged to be controlled by a rider of the watercraft. Means are provided for detecting a position of the throttle operator, and for moving said throttle device in response to the detected position of the throttle operator. Yet another aspect of the present invention involves a personal watercraft comprising a hull defining an engine compartment and an internal combustion engine disposed within the engine compartment. The engine includes an air induction system that supplies air to the engine and has a throttle device to regulate the amount of air supplied to the engine. A steering mechanism steers the watercraft and includes a handlebar assembly coupled to the hull for this purpose. A throttle device control system includes a throttle operator that is located on the handlebar assembly and is arranged to be controlled by a rider of the watercraft. An operator position sensor is mounted within the engine compartment and is configured to detect the position of the throttle operator and to output a data signal that is indicative of the detected position of the throttle operator. A controller communicates with the operator position sensor to receive the data signal and is configured to output a control signal in response to the data signal. An actuator mounted within the engine compartment communicates with the controller. The actuator also is coupled to the throttle device and is adapted to adjust the throttle device in response to the control signal from the controller.

A further aspect of at least one of the inventions disclosed herein involves a personal watercraft comprising a hull and an internal combustion engine disposed within the hull. The engine includes an air induction system that supplies air to the engine and has a throttle device to regulate the amount of air supplied to the engine. A steering mechanism controls the steering movement of the watercraft and includes a handlebar assembly coupled to the hull. A throttle device control system includes a throttle operator that is located on the handlebar assembly and is arranged to be controlled by a rider of the watercraft. Means are provided for detecting a position of the throttle operator, and for moving said throttle device in response to the detected position of the throttle operator.

Further aspects, features, and advantages of the inventions disclosed herein will become apparent from the detailed description of the preferred embodiments which follows.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the present inventions now will be described with reference to the drawings of preferred embodiments of the inventions, which are intended to illustrate and not to limit the present inventions, and in which drawings:

FIG. 1 is a partially sectioned top view of a personal watercraft, which has a throttle valve control system configured in accordance with the present invention, with some of the watercraft components and features illustrated in phantom;

FIG. 2 is a partially sectioned side view of the watercraft illustrated in FIG. 1, with some internal components of an engine and jet pump illustrated in phantom;

FIG. 3 is a cross-sectional view of the watercraft illustrated in FIG. 1, taken along the line 3—3 in FIG. 2;

FIG. 4 is a cross-sectional view of a throttle lever and throttle lever position sensor that is configured in accordance with the present invention;

FIG. 5 is partially sectioned top view of the throttle lever and throttle lever position sensor illustrated in FIG. 4; and

FIG. 6 is a schematic diagram illustrating another embodiment of a throttle valve control system configured in accordance with the present invention.

FIG. 7 is a partially sectioned and top plan view of an embodiment of a throttle control relay assembly having a throttle lever position sensor and an actuator contained within a housing.

FIG. 8 is a partial cut-away view of the throttle lever position sensor of FIG. 7.

FIG. 9 is a side elevational view of the throttle control relay assembly of FIG. 7 showing an output pulley of the actuator.

FIG. 10 is a partially sectioned view of another embodiment of a throttle lever position sensor.

FIG. 11 is a schematic representation of one embodiment of a throttle valve control system.

FIG. 12 is a partially sectioned side view of the watercraft illustrated in FIG. 1, with some internal components of an engine and jet pump illustrated, and showing another preferred location of a throttle lever position sensor of FIG. 10.

FIG. 13 is a partial view of a throttle body assembly removed from a watercraft and illustrating one embodiment of a coupling between an actuator and the throttle valves.

FIG. 14 is a schematic representation a throttle valve control system in accordance with another embodiment.

FIG. 15 is another partial view of a throttle body assembly removed from a watercraft and illustrating another embodiment of a coupling between an actuator and the throttle valves.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention generally relates to an improved engine output control system for a personal watercraft. The engine output control system is described in conjunction a personal watercraft because this is an application for which the system has particular utility. Those of ordinary skill in the relevant arts will readily appreciate that the arrangements described herein also may have utility in a wide variety of other settings, including other types of watercraft and land vehicles.

With reference now to FIGS. 1 and 2, a personal watercraft, which is indicated generally by the reference numeral 20, is illustrated therein. The watercraft 20 includes a hull 22 that is defined by a top portion or deck 24 and a lower portion 26. These portions of the hull 22 are preferably formed from a suitable material such as, for example, a molded fiberglass reinforced resin. For instance, the hull lower portion 26 can be formed using a sheet molding compound (SMC), i.e., a mixed mass of reinforced fiber and thermal setting resin that is processed in a pressurized, closed mold. The molding process desirably is temperature controlled such that the mold is heated and cooled during the molding process. For this purpose, male and female portions of the mold can include fluid jackets through which steam and cooling water can be run to heat and cool the mold during the manufacturing process.

The lower hull portion 26 and the upper deck 24 are joined around the peripheral edge at a bond flange 28. Thus, the bond flange 28 generally defines the intersection of the lower portion 26 of the hull 22 and the deck 24.

As viewed in a direction from the bow to the stem of the watercraft 20, the upper deck portion 24 includes a bow portion 30, a control mast 32, a front seat 34, a rear seat 36 and a boarding platform 38. The bow portion 30 preferably slopes upwardly toward the control mast 32. A hatch cover 40 can be provided within the bow portion 30. The hatch cover 40 preferably is pivotally attached to the upper deck 24 and is capable of being selectively locked in a closed and substantially watertight position. The hatch cover 40 covers a storage compartment 41.

The control mast 32 extends upward from the bow portion 30 and supports a handlebar assembly 44, which includes a handlebar and a pair of handlebar grips 198 that are mounted on the ends of the handlebar. The handlebar assembly 44 controls the steering of the watercraft 20 in a conventional manner. The handle bar assembly 44 also carries a variety of the controls of the watercraft, such as, for example, a start switch and a lanyard switch. Additionally, an engine output request device, such as, for example, but without limitation, a throttle lever 200, described in greater detail below, can be positioned on the handlebar next to one of the grips 198.

With continued reference to FIGS. 1 and 2, the upper deck 24 further comprises a longitudinally extending seat pedestal 48. In the illustrated arrangement, the pedestal 48 supports the front seat 34 and the rear seat 36. The front 34 and rear seats 36 are desirably of the straddle-type. A straddle-type seat is well known as a longitudinally extending seat configured such that operators and passengers sit on the seat with a leg positioned to either side of the seat. Thus, an operator and at least one passenger can sit in tandem on the

seats

34, 36. Of course, the two

seats

34, 36 can be combined in some arrangements into a single seat mounted to the raised pedestal 48. Moreover, these

seats

34, 36 are preferably centrally located between the sides of the hull 22.

As illustrated in FIGS. 1 and 3, foot areas 56 are formed alongside the pedestal 48 and are generally defined as the lower area located between the pedestal 48 and a pair of raised side gunwales or bulwarks 58 that extend along the outer sides of the watercraft 20. The foot areas 56 preferably are sized and configured to accommodate the lower legs and feet of the riders who straddle the

seats

34, 36. As described above, the illustrated watercraft 20 also includes the boarding platform 38 that is connected to the illustrated foot areas 56 and that is formed at the rear of the watercraft 20 behind the pedestal 48. The boarding platform 38 allows ease of entry onto the watercraft 20.

With reference back to FIGS. 1 and 2, the front seat 34 covers an access opening 50 that allows access into a cavity 52 defined by the hull 22. The cavity 52 formed between the two

hull sections

24, 26 is divided by one or more bulkheads. In the illustrated watercraft 20, a bulkhead 54 preferably is disposed within the hull cavity 52 to divide the cavity 52 into an engine compartment 60 and a pump compartment 61. As will be described, air ducts extend into the cavity to ventilate the cavity and to cool various components of the watercraft.

As described above, the access opening 50 is formed on a top surface of the pedestal 48 and is desirably positioned beneath at least one of the

seats

34, 36. Thus, the access opening 50, or maintenance opening, is covered by the seat 34 in a water-sealing manner. For this purpose, one or more seals 66, or gaskets, can circumscribe the opening 50.

The rear seat 36 in the illustrated embodiment covers the an electronic control unit (ECU) 113. The ECU is supported and protected by a platform 53, which is supported within the hull 22 by the bulkhead 54. The platform 53 also forms a storage compartment 51 that is also covered by the rear seat 36.

An engine 68 is mounted within the cavity 52 of the illustrated watercraft 20 using resilient mounts 69 as is well known to those of ordinary skill in the art. Although the engine 68 may be of any known type, in the illustrated embodiment and in the preferred form, the engine 68 is of the four-cycle, overhead valve type. It should be appreciated that while the illustrated engine 68 is of the four-cycle variety, the engine 68 can also be of the two-cycle, diesel, or rotary variety as well.

The general construction of a four-cycle, overhead valve type engine is well known to those of ordinary skill in the art. As illustrated in FIGS. 1 through 3, the engine 68 generally comprises a cylinder block 70, a cylinder head 72, a cylinder head cover 74, and a crankcase 76. Four in-line cylinders 78 a-d are formed within the cylinder block 70. However, the engine 68 can have one, two or more than three cylinders and can be inclined, opposed or formed with two banks of cylinders.

The cylinders 78 are capped by the cylinder head 72 and cylinder head cover 74. A piston 81 is reciprocally mounted within each of the cylinders 78 a-d and a combustion chamber 79 is defined within the cylinder 78 by the top of the piston 81, the wall of the cylinder and a recess formed within a lower surface of the cylinder head 72.

The cylinder head 72 journals a pair of overhead camshafts 180 that directly actuate the intake and

exhaust valves

182, 184 for opening and closing the intake and

exhaust passages

186, 188. The camshafts 180 are covered by a cam cover 181. The intake valves 182 permit the flow of an intake charge into the combustion chambers 79 of the engine from an induction system 102 that is disposed at one side of the cylinder head. The induction system 102 is described in more detail below. As is well-known in the art, the exhaust valves 184 govern the flow of exhaust from the combustion chamber 79.

The crankcase 76 is attached to the opposite end of the cylinder block 70 from the cylinder head 72. A crankcase chamber 80 generally is defined by the crankcase 76 and the cylinder block 70. A crankshaft 82 is positioned within the crankcase 80 and is connected to the pistons 81 through a set of connecting rods. As the pistons 81 reciprocate within the cylinders 78, the crankshaft 82 is rotated within the crankcase chamber 80.

As shown in FIGS. 1 and 2, the crankshaft 82 preferably is in driving relation with a jet propulsion unit 84 that is provided in the pump chamber 62. The pump chamber 62 is formed in part by the hull 22 and a bottom plate 91 that protects the lower side of the jet propulsion unit 84. The jet propulsion unit 84 preferably includes an impeller shaft 86 to which a propeller or an impeller 88 is attached. The crankshaft 82 and the impeller shaft 86 desirably are connected through a conventional shock-absorbing or resilient coupling 90. The impeller shaft 86 extends in the longitudinal direction through a propulsion duct 92, that can be defined by the lower portion of the hull 26. The propulsion duct 92 has a water inlet 94 positioned on a lower surface of the hull 22. The lower portion 26 of the hull 22 also includes an opening 96 in the stern of the watercraft in which a jet outlet port 98 of the propulsion unit 84 is positioned. The propulsion unit 84 generates the propulsive force by applying pressure to water drawn up from the water inlet port 94 by rotating the impeller shaft 86 and by forcing the pressurized water through the jet outlet port 98 in a manner well known to those of ordinary skill in the art.

A nozzle deflector 100 or steering nozzle is connected to the discharge nozzle 98 of the propulsion unit 84. The nozzle deflector 100 desirably moves in the left/right and vertical directions via a well known gimbal mechanism. The nozzle deflector 100 is connected to the handlebar assembly 44 through a steering mechanism and a trim mechanism (not shown), whereby the steering and trim angles can be changed by the operation of the handlebar assembly 44 and the associated trim controls.

As illustrated in FIG. 3, the engine 68 also includes an induction system 102 that is configured to guide air toward the engine 68 for combustion in each combustion chamber 80. Preferably, the air intake system includes an intake box 104 or silencer into which air from within the engine compartment 60 is drawn through an air induction inlet 105. The air is then delivered to the charge formers 110, described below.

With reference to FIG. 2, the watercraft 20 also includes a fuel system which includes a fuel tank 42 positioned within the cavity 52. An operator fills the fuel tank 42 through the fuel fill port 43. Conventional means, such as straps (not shown) secure the fuel tank 42 in position along the lower hull portion 26. The fuel is supplied from the fuel tank 42 to the charge former 110 through any suitable fuel pumping arrangement. The charge formers 110 can be carburetors or fuel injectors depending upon the application. The arrangement illustrated in FIG. 2, however, is carbureted.

The carburetors 10 vaporize and mix fuel with the intake air to form an intake charge. A throttle device 112 regulates the air flow through the induction system. In the illustrated embodiment the throttle device is a plurality of butterfly valves 112 that are located in the carburetors 110. However, one of ordinary skill in the art will understand that other types of throttle devices 112 may be used. The throttle device 112 is preferably controlled by a throttle control system in a manner that will be described in greater detail below. Ultimately, the intake charge is delivered to the combustion chamber 79 through the intake passages 186 that are formed in the cylinder head 72.

A suitable ignition system is provided for igniting the air and fuel mixture in each combustion chamber 79. Preferably, this system comprises a spark plug 114 corresponding to each cylinder 78. The spark plugs 114 are preferably fired by a suitable ignition system that is controlled by the ECU 113 as is well known to those of skill in the art. The ECU 113 is connected to the spark plugs by one or more cables 111.

Exhaust gas generated by the engine 68 is routed from the engine 68 to a point external to the watercraft 20 by an exhaust system 115 which includes the exhaust passages 188 leading from each combustion chamber 79 through the cylinder head 72. An exhaust manifold 116 or pipe is connected to a side of the engine 68. As best illustrated in FIG. 3, the exhaust manifold 116 is connected to one side of the engine 68 while the intake system of the engine 68 is connected to the opposite side of the engine 68.

The manifold 116 has a set of branches 118 each having a passage that corresponds to one of the exhaust passages 188 leading from the combustion chambers 79. The branches 118 of the manifold 116 merge at a merge pipe portion 120 of the manifold 116, which extends in a generally forward direction. The merge pipe portion 120 has a further passage through which the exhaust is routed.

An expansion chamber 122, which lies behind the engine 68 on the same side as the exhaust manifold 116, is connected to the exhaust manifold 116, preferably via a flexible member 123 such as a rubber hose. The expansion chamber 122 has an enlarged passage or chamber through which exhaust flows from the passage in the exhaust manifold 116. A catalyst (not shown) may be positioned within the expansion chamber 122.

After flowing through the expansion chamber 122, the exhaust gases flow to a water lock 130, which is located on the opposite side of the watercraft 20. The expansion chamber 122 is preferably connected to the water lock 130 via a flexible hose 131. The exhaust gases flows through the water lock 130, which is preferably arranged in a manner well known to those of ordinary skill in the art, to prevent the backflow of water through the exhaust system to the engine 68. The exhaust gases then pass through a water trap 132, which extends over the pump chamber 62 to the other side of the watercraft 20. The water trap 132 has its terminus on a side of the pump chamber 62.

As shown in FIGS. 1 and 2, most of the expansion chamber 122 and the entire water lock 13 are located in the pump compartment 61, which is formed in part by the bulkhead 54 and lies behind the engine compartment 60. Because of the exhaust gases, the expansion chamber 122 and the water lock 120 are relatively hot. An advantage of the illustrated watercraft 20 is that these hot components are separated from the engine by the bulkhead 54. The platform 53, which is located above the pump compartment 61 also isolates the ECU from these hot components. Another advantage of the illustrated watercraft 20 is that the both the flexible hose 130 and the water trap 132 extend up and across the watercraft 20 and over (i.e., at a vertical position higher than) the pump chamber 62. This configuration prevents water that has entered the exhaust system from reaching the engine 68, especially when the watercraft 20 is capsized.

The engine 68 includes a suitable lubricating system for providing lubricant to the various moving parts of the engine Specifically, an lubrication supply tank 134 is provided on a side of the engine 68 opposite the exhaust system 115 and below the induction system 102. The lubricant tank 134 is filled through the lubricant filler port 127 that extends from the top of the tank 134. A supply hose 135 connects the supply tank 124 to a supply pump 136. The supply pump 136 delivers lubricant to circulating passages 138 within the engine 68. A lubrication filter 139 is preferably inserted into the lubrication path to clean the lubricant as is well known in the art. A lubrication pan 137 that is located at the bottom of the crankcase 76 collects the used lubricant. A scavenge pump 133 returns lubricant in the lubrication pan 137 to the supply tank 134. The scavenge pump 133 is connected to the lubrication tank by a return hose 129.

The engine 68 can also include a suitable liquid and/or air cooling system. Moreover, the watercraft 20 can include a bilge system for drawing water from within the hull cavity 52 and discharging it into the body of water. These systems are well known in the art and their description is not necessary for an understanding of the present throttle control system.

Preferably, air is drawn into the engine compartment 60 through several air ducts. As illustrated, a forward air duct 140 is positioned in front of the engine 68 near the front end of the watercraft 20, and an aft air duct 142 is positioned behind the engine 68 towards the stem of the watercraft 20. As will be recognized, the number of

ducts

140, 142 is not critical and can be varied as desired depending upon the application. Due to the strategic locations of the forward duct 140 and the aft duct 142 in general, an air current can be set up within the engine compartment 60 to induce a flow of air across at least a portion of the engine 68; however, such a cross-current need not be used to cool the engine.

The personal watercraft so far described is conventional and represents only an exemplary personal watercraft on which the present throttle control system can be employed. Therefore, a further description of the personal watercraft is not believed necessary for an understanding and appreciation of the present invention.

The engine output control system will now be described with reference to FIGS. 1, 2, 3, 4, and 5. The engine output control system comprises the throttle lever 200, a throttle lever position sensor 202, and a throttle valve actuator 204. In the illustrated embodiment, as shown in FIG. 1, the throttle lever 200 is positioned on the handlebar assembly 44 near the right grip 198. The throttle lever 200 can, however comprise other types of operators, such as, for example, but without limitation, a thumb trigger, a push button, a twist grip, a pedal or the like. The throttle operator also can be located else where on the watercraft 20 and/or assume a variety of orientations on the watercraft in order to ease operations. For instance, in the illustrated embodiment, the throttle lever 200 is arranged to rotate about an axis that lies generally normal to an axis of the portion of the handlebar assembly 44 to which it is attached and/or to an axis of the hand grip 198. The throttle lever in some forms can be arranged to move parallel relative to or obliquely with respect to, or about the axis of the portion of the handlebar assembly 44 to which it is attached and/or to an axis of the hand grip 198, e.g., rotation about an axis that coincides with the axis of the hand grip 198, as in the case of a twist grip. In any of these embodiments, the lever 200 provides a manually operable input device for allowing an operator of the watercraft 20 to issue a power output request, i.e., the position to where the lever 200 is moved corresponds to a power output desired by the operator. Thus, when the operator wishes more power output from the engine 68, the operator can squeeze and thereby further deflect the lever 200.

In the illustrated embodiment, the throttle lever position sensor 202 is also located on the handlebar assembly 44 near the right grip 198; however, it could also be located elsewhere on the watercraft. In one variation, for instance, the throttle lever position sensor 202 can be located within the hull and be coupled to the throttle lever 200 by an interposed mechanism.

The throttle valve actuator 204 preferably is located within the cavity 52 of the hull 22. As will be described in detail below, the throttle lever position sensor 202 indicates the position of the throttle lever 200 to the throttle valve actuator 204. The throttle valve actuator 204 opens and closes the throttle valves 112 in response. Accordingly, the throttle lever 200 indirectly controls the position of the throttle valves 112.

With reference to FIGS. 4 and 5, the throttle lever 200 includes an elongated shaft 206 that is suitably journaled for rotation within a case 208. The case 208 preferably is substantially waterproof and preferably made of a resin based material. A nut 210 is attached to a threaded portion 212 of the shaft 206 and prevents the throttle lever 200 from being lifted out of the case 208. One or more seals 212 surround the shaft 206 and prevent water from entering the case 208.

With reference to FIG. 4, an internal wall 214 divides the case 208 into an upper chamber 216 and a lower chamber 218. The upper chamber houses a torsional spring 220 that is attached to the elongated shaft 206. The spring 220 biases the throttle lever 200 to the traditional idling position, which is indicated by line I of FIG. 5. The lower chamber 218 houses the throttle lever position sensor 202, which will be described in detail below.

As shown in FIG. 1, the case 208 is mounted to a fixture 222 that is attached to the handlebar assembly 44 next to the right hand grip 198. As best seen in FIG. 5, the fixture 222, the case 208, and the throttle lever 200 are arranged such that the operator can grasp the handlebar grip 198 and actuate the throttle lever 200 with her index finger 224. By squeezing her index finger 224, the operator can rotate the throttle lever 200 from the idling position to the full throttle position (indicated by line FT of FIG. 5). When the operator releases the throttle lever 200, the spring 220 returns the throttle lever 200 to the idling position.

With reference back to FIGS. 4 and 5, the throttle lever position sensor 202 is formed within the lower chamber 218. In the illustrated arrangement, the components of the throttle lever position sensor 202 form a rheostat. A rheostat is a current-setting device in which one terminal is connected to a resistive element and the second terminal is connected to a movable contact to place a selective section of the restive element into the circuit. The current set by the rheostat comprises the signal indicating the position of the throttle lever 200. It should be appreciated that other circuits could be used in the throttle lever position sensor 202, such as, for example, a potentiometer. In such a system, the voltage set by the potentiometer would indicate the position of the throttle lever 200. However, the illustrated throttle lever position sensor 202 is preferred because it uses a small number of parts and is particularly suited for rugged use.

The components of the illustrated arrangement of the throttle lever position sensor 202 will now be described. In the lower chamber 218, a movable contact 228 is attached to an arm 230. The arm 230 includes annular sleeve 231 that includes slots (not shown). The sleeve 231 fits over splines 232 formed on the lower end of the elongated shaft 206. A C-ring 231 secures the sleeve 231 at an axial position along the elongated shaft 206. Because the arm 230 and the elongated shaft 206 are coupled together, the movable contact 228 rotates with the throttle lever 200.

The moveable contact 228 is made of conductive material, such as, for example, copper. The moveable contact 228 includes a first contact point 234 and a second contact point 236. The first contact point 234 contacts a resistive element 238, which is attached to a lower surface 233 of the lower chamber 218. The resistive element 238 can be manufacture as, for example, a carbon composition film, a metallic film, or a wire-wound resistor. As shown in FIG. 5, the resistive element 238 is arc-shaped. Accordingly, as the throttle lever 200 is rotated, the first contact point 234 remains in contact with the resistive element 238.

The second contact point 236 of the moveable contact 228 contacts a stationary contact 240 that is mounted to a side wall 237 of the case 208. The side wall 237 and the stationary contact 240 are also arc-shaped such that as the throttle lever 200 rotates the second contact 236 stays in contact with the stationary contact 240. The stationary contact 240 is also made of a conductive material such, for example, copper.

A first electric wire 242 is connected the resistive element 238. Similarly, a second electric wire 244 is connected the stationary contact 240. Both

wires

242, 244 are protected by a casing 243. The

wires

242, 244 are routed through the watercraft 20 and are connected to the ECU 113. A closed circuit consisting of the ECU 113, the first wire 242, the resistive element 238, the moveable contact 228, the stationary contact 240, and the second wire 244 is formed. The ECU 113 supplies a voltage to the circuit.

The current i in the circuit indicates the position of the throttle lever 200 as will be explained below. When the throttle lever 200 is in the idling position, a large portion of the resistive element 238 is placed into the circuit. Accordingly, the circuit has relatively large total resistance R_I. Consequently, for a given voltage, the current i_Iflowing through the circuit will be relatively small according to the equation V=iR.

In comparison, when the throttle lever 200 is in the full-throttle position, a smaller portion of the resistive element 238 is placed into the circuit. Accordingly, the total resistance R_FTof the circuit is less than the total resistance R_Iof the circuit in the idling position. Consequently, the current i_FTflowing through the circuit is larger than the current i_Iflowing through the circuit in the idling position. Thus, for a given voltage the current i indicates the position of the throttle lever 200 in accordance with the linear relationship between i and R. The ECU 113 senses the current and determines the position of the throttle lever.

A wire 254 connects the ECU 113 to the valve actuator 204, which is located in the engine cavity 60 in front of the engine 68 (FIG. 1). The valve actuator 204 comprises a prime mover (not shown), such as, for example, a stepper motor or a servo motor. The actuator also includes a pulley 250. Bowden-wire cables 252 are coupled to the pulley 250 and the throttle valves 112 such that rotation of the pulley 250 causes the throttle valves 112 to open and close. The throttle valve actuator 204 opens and closes the throttle valves 112 in response to a signal generated by the ECU 113.

When the throttle lever 200 is in the idling position, the current i in the circuit is relatively small as explained above. The ECU 113 senses the small current and sends a signal to the actuator 204 to adjust the throttle valves 112 to the idling position. As the throttle lever 200 is moved towards the full throttle position, the current i in the circuit increases. In response, the ECU 113 sends a signal to the actuator 204 to open the throttle valves 112. In this manner, the throttle lever 200 indirectly controls the position of the throttle valves 112.

As shown in FIG. 1, a meter 256 is connected to the circuit by a wire 258; alternatively, the meter 256 is connected to the ECU 113. The meter 256 is mounted onto the control mast 46 and indicates the position of the throttle lever 200 according either the current in the circuit or a signal generated by the ECU 113 in response to the current in the circuit.

From the above description, it is readily apparent that the illustrated power output control system has several advantages as compared to prior art control systems. For example, prior art throttle valves are normally biased to an idling position by return springs. These return springs generally are relatively stiff in order to overcome the force of air flow across the throttle valve. The prior art throttle levers are typically directly coupled to the throttle valve. Accordingly, the operator must hold the throttle lever against the force of the return springs in order to maintain a specific speed. In comparison, the throttle lever 200 in the illustrated throttle control system indirectly controls the throttle valves 112. That is, the actuator 204 opens and closes the throttle valves in response to the detected position of the throttle lever 200. The return spring 220 returns the throttle lever 200 to the idling position. Accordingly, the return spring 220 can be designed to be significantly weaker than the throttle valve return springs of the prior art. Accordingly, the throttle lever 200 has a “light touch” and the operator's fingers becomes less tired after holding the throttle lever 200 for a long period of time.

FIG. 6 is a schematic illustration of another arrangement of a throttle valve control system according to the present invention. The control system includes a throttle lever 200, a throttle lever position sensor 202, and an actuator 204. These components are arranged essentially as described above. The throttle lever position sensor 202 determines the position of the throttle lever 200. The throttle valve actuator 204 opens and closes the throttle valves 112 in response to the detected position of the throttle lever 200. Accordingly, the throttle lever 200 indirectly controls the position of the throttle valves 112.

The throttle lever 200 is also configured to directly adjust the throttle valves 112. As shown in FIG. 6, the throttle lever 200 is connected by a means such as a Bowden-wire cable 262 to a lost motion device 264. A wide variety of lost motions devices, which are well known in the art, can be used in accordance with the present invention. Lost motion devices are typically inserted between two elements whereby the motion of one element is to be partially transferred to the other. The lost motion device absorbs the motion of the first element for a range of motion and transfers motion to the second element for another range of motion. For example, a spring can be inserted between two elements. The spring absorbs motion the motion of the first element until the spring is completely compressed. Once compressed, the motion of the first element is transferred to the second element. As shown in FIG. 6, the illustrated lost motion device 264 is connected to the throttle valves 112 by a means such as a Bowden-wire cable 262.

Desirably, the lost motion device 264 absorbs the motion of the Bowden-wire cable 262 when the throttle lever 200 is moved from the idling position to a planing speed position. Accordingly, the throttle lever 200 does not directly open the throttle valves 112 until the watercraft 20 reaches a planing state. Instead, the throttle lever position sensor 202 detects the position of the throttle lever 200 and the ECU 113 instructs the actuator 204 to adjust the position of the throttle valves 112.

Once the throttle lever 200 passes the planing speed position, the lost motion device 264 no longer absorbs the motion of the throttle lever 200. The throttle lever 200 now directly adjusts the position of the throttle valves 112. Correspondingly, the ECU 113 instructs the actuator 204 to no longer control the position of the throttle valves 112.

This arrangement has several advantages. For example, the control system can be configured such that to achieve planing speeds, the throttle lever 200 only has to be rotated a small distance. That is, the actuator 200 can be configured to open the throttle valves 112 to a planing speed position in response to a small movement of the throttle lever 200. Because personal watercraft 20 are operated mostly in the planing mode, this arrangement is beneficial because it provides the throttle lever 200 with a larger useful range of motion. Accordingly, it is easier for the operator to keep the watercraft 20 in the planing state.

It should also be appreciated that the arrangement of FIG. 6 can also be reversed. That is, the control system can be configured such that the throttle lever 200 directly adjusts the throttle valves 112 until the watercraft 20 reaches a planing state. After a planing state is reached, the lost motion device 262 absorbs the motion of the throttle lever 200 and the throttle lever 200 no longer directly adjust the throttle valves 200. Accordingly, during planing the throttle valves 112 are controlled by the ECU 113 and adjusted by the actuator 204. This arrangement ensures that the throttle lever has a “light touch” during planing speeds. Accordingly, the operator's fingers do not tire during long trips.

With reference to FIGS. 7-8 another embodiment of a power output control is illustrated. This embodiment utilizes several components that generally correspond with other embodiments already described herein and as such, like reference numerals will be used to designate like components.

A power output control assembly 300 includes a throttle lever position sensor 202 in communication with the throttle lever 200 (FIG. 4) and a throttle valve actuator 204. As discussed above, the throttle lever 200 is positioned on the handlebar assembly 44 near the right grip 198. Of course, the throttle lever 200 can comprise other types of operators, such as, for example, but without limitation, a thumb trigger, a push button, a twist grip, a pedal or the like. The throttle operator 200 also can be located else where on the watercraft 20 and/or assume a variety of orientations on the watercraft in order to ease operations. In any of these positions and configurations, as noted above, the operator can use the throttle lever 200 as an input for a power output request. Thus, when an operator desires more power output from the engine 68, the operator can squeeze the lever 200, and thereby issue a signal to the power output control assembly 300 for causing the engine 68 to increase its power output.

The throttle lever 200 is in communication with the throttle lever position sensor 202 such as through a throttle cable 302, or other suitable connection designed to transmit a force to the throttle lever position sensor 202, discussed in greater detail below.

The power output control assembly 300 preferably is located within the cavity 52 of the hull 22. As described in detail below, the throttle lever position sensor 202 detects the position of the throttle lever 200 and transmits a signal indicative thereof to the throttle valve actuator 204. The throttle valve actuator 204 opens and closes the throttle valves 112 in response. Accordingly, the throttle lever 200 indirectly controls the position of the throttle valves 112, and thereby, the power output from the engine 68.

With continued reference to FIGS. 7-9, the throttle lever position sensor 202 includes an elongated lever 304 with a depending shaft 308 that is suitably journaled for rotation within a housing 306. The housing 306 is substantially waterproof and preferably made of a polymeric or resin based material. A nut 310 is attached to a threaded portion 312 of the shaft 308 and prevents the lever 304 from being lifted out of the housing 306. One or more seals 313 surround the shaft 308 and prevent water from entering the hole 315 formed in the upper surface 317 of the housing 306.

The lever 304 has a through hole 307 (of FIG. 8) formed toward an end thereof and is configured to receive and secure an end of the throttle cable 302 a. In the illustrated embodiment, the throttle cable 302 a extends through the hole 307 and has a barrel 309 attached thereto to inhibit the throttle cable 302 a from withdrawing from the hole 307 in the lever 304. The opposing end of the throttle cable 302 a is connected to the throttle lever 200, as is generally known in the art. Thus, movement of the throttle lever 200 toward a full throttle position will tension the throttle cable 302 a, which in turn, will displace the lever 304. Thus, displacement of the throttle lever 200 is translated into displacement of the lever 304 of the throttle lever position sensor 202. Of course, other suitable methods of connecting the throttle cable 302 a to the lever 304 will be recognized. For example, a push rod could be substituted to transmit both push and pull forces, a pull—pull cable configuration could be used to force the lever 304 to rotate, or a torsion cable could transmit rotating forces. Additionally, the throttle cable 302 a can be connected to the lever 304 through other suitable methods, such as tying, adhesives, or otherwise affixing it to the lever 304.

An internal wall 314 divides the housing 306 into an upper chamber 316 and a lower chamber 318, as viewed in FIG. 7. However, it is to be noted that FIG. 7 is a partial top plan and sectional view of the assembly 300. Thus, the upper chamber 316 is disposed on the starboard side of the assembly 316, and the lower chamber 318 is disposed on the port side. These special relationships are also true for other components noted below referred to as “upper” and “lower” as well. Further, the illustrated orientation is merely one example of numerous other positions and orientations in which the assembly 300 can be placed.

Within the upper chamber 316 is a substantially watertight case 320 containing the throttle lever position sensor 202. The lower chamber 318 houses the actuator 204.

The case 320 is joined to the upper chamber, such as by a bolt 322 at a mating flange 324. The case 320 further has a partition 326 running therethrough with a hole 328 formed therein configured to receive the lever shaft 308. The partition 326 thus separates the case into an upper partition 327 and lower partition 329. A torsional spring 220 is connected to the lever shaft 308. The spring 220 biases the lever shaft 308 to a position corresponding with a throttle idle position, which is indicated by line I of FIG. 8. The lower partition 329 houses the electronics of the throttle lever position sensor 202.

In the illustrated arrangement, the components of the throttle lever position sensor 202 form a rheostat. A rheostat is a current-setting device in which one terminal is connected to a resistive element and the second terminal is connected to a movable contact to place a selective section of the restive element into the circuit. The current set by the rheostat comprises the signal indicating the position of the throttle lever 200. It should be appreciated that other circuits could be used in the throttle lever position sensor 202, such as, for example, a potentiometer. In such a system, the voltage set by the potentiometer would indicate the position of the throttle lever 200. However, in the illustrated embodiment of the throttle lever position sensor 202, a rheostat is preferred because it uses a small number of parts and is particularly suited for rugged use.

The throttle lever position sensor 204 comprises a movable contact 228 attached to an arm 230. The arm 230 includes annular sleeve 231 that includes slots (not shown). The sleeve 231 fits over splines 332 formed on the lower end of the shaft 308. A C-ring 330 secures the sleeve 231 at an axial position along the shaft 308. Because the arm 230 and the shaft 308 are spline coupled together, the movable contact 228 rotates with the lever 304, which rotates in response to rotation from the throttle lever 200.

The moveable contact 228 is made of conductive material, such as, for example, copper. The moveable contact 228 includes a first contact point 234 and a second contact point 236. The first contact point 234 contacts a resistive element 238, which is attached to a lower surface 233 of the lower partition 329. The resistive element 238 can be manufactured from any suitable material such as, for example, a carbon composition film, a metallic film, or a wire-wound resistor. As shown in FIG. 8, the resistive element 238 is arc-shaped. Accordingly, as the throttle lever 200 is rotated, the first contact point 234 remains in contact with the resistive element 238.

The second contact point 236 of the moveable contact 228 contacts a stationary contact 240 that is mounted to a side wall 237 of the housing 306. The side wall 237 and the stationary contact 240 are also arc-shaped such that as the throttle lever 200 rotates the arm 230, the second contact 236 stays in contact with the stationary contact 240. The stationary contact 240 is also made of a conductive material such, for example, copper.

A first electric wire 242 is connected to the resistive element 238. Similarly, a second electric wire 244 is connected to the stationary contact 240. Both

wires

242, 244 are protected by a casing 243 and are routed through the watercraft 20 and connect to the ECU 113. A closed circuit consisting of the ECU 113, the first wire 242, the resistive element 238, the moveable contact 228, the stationary contact 240, and the second wire 244 is formed. The ECU 113 supplies a voltage to the circuit and detects a current through the closed circuit.

The current i in the circuit indicates the position of the throttle lever 200 as will be explained below. When the throttle lever 200 is in the idling position, a small portion of the resistive element 238 is placed into the circuit. Accordingly, the circuit has a relatively small total resistance R_I. Consequently, for a given voltage, the current i_Iflowing through the circuit will be relatively large according to the equation V=iR. According to the equation, for a given V, i is inversely proportional to R.

In comparison, when the throttle lever 200 is in the full-throttle position, a larger portion of the resistive element 238 is placed into the circuit. Accordingly, the total resistance R_FTof the circuit is greater than the total resistance R_Iof the circuit in the idling position. Consequently, the current i_FTflowing through the circuit is smaller than the current i_Iflowing through the circuit in the idling position. Thus, for a given voltage the current i indicates the position of the throttle lever 200 in accordance with the linear relationship between i and R. The ECU 113 senses the current and determines the position of the throttle lever.

A wire 254 connects the ECU 113 to the actuator 204 located in the lower chamber 318. The lower chamber 318 is substantially watertight and is formed of sidewalls 342, the partition 314, and a lower wall 344. Preferably, one of the walls has a hole 346 formed therethrough to allow the passage of the wire 254. Preferably, a seal 348 surrounds the wire 254 and fills the hole 346 to maintain the water tightness of the lower chamber 318. Additionally, another hole 350 is formed into a wall 344 of the lower chamber 318 to provide a passage for a portion 352 of the actuator 204. In the illustrated embodiment, the actuator 204 comprises an electric motor 354, such as a stepper motor or servo motor. A seal 356 preferably surrounds the protruding portion of the actuator 204, which in the illustrated embodiment is a motor output shaft 352.

With additional reference to FIG. 9, the actuator further includes a pulley 250. Bowden-wire cables 252, or other suitable cables, are coupled to the pulley 250 and the throttle valves 112 such that rotation of the pulley 250 causes the throttle valves 112 to open and close. The throttle valve actuator 204 opens and closes the throttle valves 112 in response to a signal generated by the ECU 113.

When the throttle lever 200 is in the idling position, the current i in the circuit is relatively large as explained above. The ECU 113 senses the large current and sends a signal to the actuator 204 to adjust the throttle valves 112 to the idling position. As the throttle lever 200 is moved towards the full throttle position, the current i in the circuit decreases. In response, the ECU 113 sends a signal to the actuator 204 to open the throttle valves 112. In this manner, the throttle lever 200 indirectly controls the position of the throttle valves 112. Of course, it will be recognized that moving the throttle lever to the idle position could produce a small current, rather than a large current as described.

With reference to FIG. 10, an alternative arrangement of the throttle lever position sensor 202 is shown that is separate from the actuator 204. In the illustrated embodiment, the throttle lever position sensor 202 comprises the basic configuration as other embodiment described herein. Namely, a housing 306 is formed to be substantially watertight and is formed of any suitable material. The housing includes an upper wall 317 and a lower wall 324 having a mounting flange configured to receive a bolt 322 and nut 323 to effect mounting. The housing 306 may be mounted in any suitable location, for example, below the control mast 44 against upper deck 24 within the engine compartment 60.

A partition 326 is provided to separate the housing 306 into an upper partition 327 and a lower partition 329. The interior components of the housing 306, including the shaft 308, torsion spring 220, and electronic components are substantially the same as described above with reference to alternative embodiments. Thus, further description of the specific configuration of the components contained within the housing 306 is not believed to be necessary. It is sufficient to note that the illustrated configuration of the housing of FIG. 10 allows the throttle lever position sensor 202 to be mounted almost anywhere about the watercraft 10 because its construction and mounting are independent of the throttle lever 200 and the actuator 204. This provides greater flexibility for placing the throttle lever position sensor 202 in advantageous locations, such as in locations that offer greater protection from jarring during watercraft operation, reduced exposure to water, or allow easy maintenance access. One such suitable location is generally below the control mast 32 and against the deck 360 (of FIG. 2) within the engine compartment 60.

With reference to FIG. 11, a throttle lever 200 is mounted adjacent the grip 198 of the handlebar assembly. The throttle lever 200 is operatively coupled to the throttle lever position sensor 202 as described herein, which may be by a throttle cable 302. The throttle lever position sensor 202 is configured to detect the position of the driver-controlled throttle lever 200 and send a corresponding signal to the ECU 113 via a conducting wire 362. The ECU, in turn, is in communication with the actuator 204 via a conducting wire 364.

As described herein, the actuator 204 is coupled to the throttle valves 112, such as by a pulley and a pull—pull cable 252 type connection to transmit a rotational output of the actuator 204 to the throttle valves 112. Thus, the throttle lever 200 indirectly determines the position of the throttle valves 114 through electronic signals generated and sent between the throttle lever position sensor 204, the ECU 113, and the actuator 204, and a mechanical coupling between the actuator 204 and the throttle valves 113.

The throttle valves 112 are coupled together for simultaneous rotational movement by a throttle valve shaft 366. The throttle valves 112 are rotatable within the air intake system between substantially closed positions and fully open positions corresponding with idle and full throttle engine operating conditions, respectively. The engine 68 receives a volume of intake air that is regulated by the position of the throttle valves 112. Where a fuel injection system (not shown) is used to form fuel charges, the amount of injected fuel is determined by a desired air/fuel mixture ratio and is injected into the air flow moving through the associated throttle bodies, or directly into the combustion chambers and thereby determines the ferocity of the combustion process, and hence, the engine speed. Thus, the throttle lever 200 indirectly controls the position of the throttle valves 112 and hence, the engine speed.

A throttle position sensor 368 is provided to detect the position of the throttle valves 112 and send a corresponding signal to the ECU 113. As discussed above in relation to FIG. 10, the throttle lever position sensor 202 need not be mounted adjacent the actuator 204, but can be mounted remotely. However, while the throttle lever position sensor 202 may be mounted anywhere about the watercraft, it is preferably mounted within the hull 22, and even more preferably within the engine compartment 60.

In the illustrated embodiment of FIG. 11, the actuator can be connected directly to the throttle shaft 366. For example, the shaft 352 of the motor 354 can be directly keyed to the throttle valve shaft 366 so as to directly drive the throttle valve shaft 366. As such, certain components, such as the additional pulleys and cables utilized in the embodiment of FIG. 9, can be eliminated, thereby reducing cost. Additionally, where the integrated assembly 300 is used, the entire assembly 300 can be mounted in the vicinity of an end of the throttle valve shaft 366, so as to allow the actuator 204 can be keyed to the throttle valve shaft 366 as noted above.

With reference to FIG. 12, one embodiment of a watercraft advantageously locates the throttle lever position sensor 202 within the engine compartment 60 at a location forward of the engine 68 and beneath the control mast 32 against the inner wall of the upper deck 24, designated generally by the reference numeral 360 (of FIG. 2).

With reference to FIG. 13, an alternative location of the actuator 204 is illustrated. The throttle valves 112 are each located within an intake passage 186 to control the flow of induction air therethrough. The throttle valves 112 are connected together by a throttle valve shaft 366 for concurrent rotational movement within their respective intake passages 186. As described above, an actuator 204 receives a signal from the ECU 113, such as an electric signal traveling through a wire 364, and instructs the actuator 204 to rotate the throttle valves 113.

In the illustrated embodiment, the actuator is an electric motor 354 having an output shaft 352. A motor output gear 370, or motor gear, is attached to the output shaft 354 and configured to rotate therewith. A throttle valve gear 372 is mounted on one end of the throttle valve shaft 366 and is configured for concurrent rotation therewith. The throttle valve gear 372 is disposed in meshing engagement with the motor gear 370. Thus, as the motor 354 turns the motor gear 370, a rotational force is imparted to the throttle valve gear 372, which turns the throttle shaft 366 and the attached throttle valves 112.

The meshing gears 370, 372 can be of any common diametral pitch, so as to maintain their meshing engagement. Additionally, in one embodiment, it is preferred that the motor output shaft 352 is substantially parallel with the throttle valve shaft 366 to enable a simple gear mesh between the

gears

370, 372. To further enhance the simplicity of maintaining an effective meshing of the

gears

370, 372, one embodiment utilizes gears having an involute profile, which is relatively easy to manufacture, and does not require strict tolerances between the respective gear shafts. Of course, other gear types could be used, such as, for example, helical gears, bevel gears, or any such suitable configuration could be used with parallel or nonparallel gear shafts.

In one embodiment, the gear ratio is 1:1 so that an angular displacement a of the motor gear 370 results in a rotation of the throttle valve gear 372 the same angle a. In other embodiments, step down gearing is used to reduce the relative angular velocity of the throttle valve shaft 366 in comparison with the motor output shaft 352. In this case, the motor gear 370 would be smaller than the throttle valve gear 372. In other embodiments, step up gears are used in which the motor gear 370 is larger than the throttle valve gear 372. This particular configuration provides very fast response of the throttle valves 112 because the throttle valve gear 372 is configured to turn faster than the motor gear 370. However, while it results in a fast response time from the throttle valves 112, the precision of the throttle valve position is reduced.

For example, assuming the motor 354 is accurate and steppable through one degree increments, the throttle valve gear 372 would be steppable through increments corresponding with the gear ratio. For instance, if the gear ratio were 1:2, a one degree rotation of the motor gear 370 would result in a two degree rotation of the throttle valve gear 372. Thus, the throttle valve gear 372 would only be steppable through 2 degree increments in this configuration. However, any suitable and desired gear ratio can be selected based upon the combination of the desired speed and accuracy of the throttle valve position and upon the characteristics of the actuator 354.

With reference to FIG. 14, another embodiment illustrates an arrangement of an engine and an associated power output control. As illustrated, a single throttle valve 112 is mounted in an induction system of the engine 68. A throttle lever position sensor 202 is mounted remotely from the throttle lever 200 and grip 198. The throttle lever position sensor 202 is in communication with the ECU 113 through a wire 362.

As described above, the throttle lever position sensor 202 detects the position of the throttle lever 200 and sends a corresponding signal to the ECU 113, which then sends a control signal to the actuator 204 through a wire 364. The actuator 204 then controls the throttle valve 112 and adjust its opening degree in response to the signal sent by the ECU 113.

The illustrated embodiment shows a single throttle valve 112 rotatably mounted on a throttle valve shaft 366. The actuator 204 can be coupled to the throttle valve shaft 366 in any suitable manner. For example, the actuator 204 can be directly connected to the throttle valve shaft 366, or can have an interposed coupling, such as meshing gears, or a cable system as already described. Of course, other suitable methods of transmitting the output of the actuator 204 to the throttle valve 112 are possible and will become readily apparent to one of ordinary skill in the art in light of the disclosure herein.

The throttle lever position sensor 202 can be suitably mounted anywhere on or within the watercraft. It is preferable that the throttle lever position sensor 202 is encased in a substantially watertight housing or case. Therefore, many preferred embodiments disclosed herein describe a waterproof case configured to house the components that make up the throttle lever position sensor 202. Additionally, because in many embodiments the throttle lever position sensor 202 is connected to the throttle lever 200 by a single cable or wire, there are relatively few constraints on the required positioning of the throttle lever position sensor 202.

Likewise, there are relatively few constraints on the required positioning of the actuator. However, it is desirable to provide a substantially watertight case to house the actuator 204. Therefore, many embodiments disclosed herein describe a substantially watertight or waterproof case designed to house the components of the actuator 204. Many embodiments also describe that it is preferable that the actuator 204 is located within close proximity to the throttle valves 112 because there is usually a mechanical coupling between the two. The mechanical coupling can be of any suitable type configured to translate the output of the actuator 204 into adjustment of the throttle valve 112 position. In some embodiments, this mechanical coupling is in the form of a gear pair. Other embodiments utilize a direct connection of the actuator 204 output, such as a motor output shaft, to the throttle valve shaft 366. Still, other embodiments describe the use of Bowden-wire type cable connections to transmit a rotational force from the actuator 204 to the throttle valves 112.

According to the embodiment of FIG. 15, throttle valves 112 are connected to a common rotatable throttle valve shaft 366. The throttle valves 112 are positioned within air intake passages 186 and configured to vary their opening degree to regulate the flow of intake air through the intake passages 186. One end of the throttle valve shaft 366 carries a throttle pulley 374 that is constrained to rotate with the throttle valve shaft 366 and accompanying throttle valves 112. An actuator, such as a motor 354, is mounted adjacent the throttle valves 112 and is operatively coupled to the throttle valve shaft 366.

In the illustrated embodiment, the motor 354 has an output shaft 352 that is configured for rotation with the motor 354. The output shaft 352 further carries a motor pulley 250 that is likewise rotatable by the motor 354. The motor pulley is coupled to the throttle pulley 374 by any suitable connection 376. As described above, alternative embodiments use various methods of effecting the operative coupling between the motor pulley 250 and throttle valve shaft 366. For example, the connection 376 is in the form of a push-pull cable, a Bowden-wire type cables, other types of pull—pull cable arrangements, a belt-drive system utilizing any suitable belt configuration and cross section, or other suitable connection methods which will allow the output of the motor 354 to be transferred into throttle valve 112 adjustment.

From the foregoing description, it is readily apparent that the illustrated throttle control system embodiments have several advantages over prior art control systems. For example, prior art throttle valves are normally biased to an idling position by return springs. These return springs are generally relatively stiff in order to overcome the force of air flow across the throttle valve. The prior art throttle levers are typically directly coupled to the throttle valve. Accordingly, the operator must hold the throttle lever against the force of the return springs in order to maintain a desired speed. In comparison, the throttle lever 200 in the illustrated embodiments of the throttle control system indirectly controls the throttle valves 112. That is, the actuator 204 opens and closes the throttle valves in response to the detected position of the throttle lever 200. The return spring 220 returns the throttle lever 200 to the idling position. The return spring is not balanced against the closing force on the throttle valves 112 due to airflow. Accordingly, the return spring 220 can be designed to be significantly weaker than the throttle valve return springs of the prior art. Accordingly, the throttle lever 200 has a “light touch” and the operator's fingers becomes less tired after holding the throttle lever 200 for a long period of time.

Of course, the foregoing description is that of certain features, aspects and advantages of the present invention to which various changes and modifications may be made without departing from the spirit and scope of the present invention. Moreover, a watercraft need not feature all objects of the present invention to use certain features, aspects and advantages of the present invention. The present invention, therefore, should only be defined by the appended claims.

Claims

What is claimed is:

1. A watercraft comprising a hull, an internal combustion engine disposed within the hull, the engine including an air induction system configured to guide air to the engine and which includes a throttle device to regulate an amount of air supplied to the engine, a steering mechanism including a handlebar assembly coupled to the hull, and a throttle device control system that includes a throttle operator located on the handlebar assembly and arranged to be controlled by a rider of the watercraft, an operator position sensor that is configured to detect the position of the throttle operator and to output a signal indicative of the detected position of the throttle operator, an electronic controller communicating with the operator position sensor to receive the signal and being configured to output a control signal in response to the data signal, an actuator communicating with the controller and being coupled to the throttle device, the actuator being configured to adjust the throttle device in response to the control signal from the controller, the operator position sensor and the actuator being disposed within the hull.

2. The watercraft of claim 1, further comprising a waterproof housing mounted within the engine compartment and wherein the operator position sensor and the actuator are located within the waterproof housing.

3. The watercraft of claim 2, wherein the waterproof housing defines a first compartment and a second compartment, the operator position sensor being located in the first compartment, and the actuator located within the second compartment.

4. The watercraft of claim 1, further comprising a first waterproof housing and a second waterproof housing, the first waterproof housing containing the operator position sensor and the second housing containing the actuator.

5. The watercraft of claim 1, wherein the actuator comprises a motor mounted adjacent to the engine, the motor having a rotational output shaft.

6. The watercraft of claim 5, wherein the throttle device comprises a throttle valve coupled to a throttle shaft, the throttle shaft journaled for rotation, and wherein the rotational output shaft is operatively coupled to rotate the throttle shaft.

7. The watercraft of claim 6, wherein the rotational shaft is operatively coupled to rotate the throttle shaft through a meshing gear pair.

8. The watercraft of claim 6, wherein the rotational shaft is operatively coupled to rotate the throttle shaft through a pull—pull cable assembly.

9. The watercraft of claim 6, wherein the rotational shaft is operatively coupled to rotate the throttle shaft through a belt drive system.

10. A small watercraft comprising a hull, an internal combustion engine disposed within the hull, the engine including an air induction system configured to guide air to the engine and which includes a throttle device configured to regulate the amount of air supplied to the engine, a steering mechanism including a handlebar assembly coupled to the hull, and a throttle device control system that includes a throttle operator located on the handlebar assembly and arranged to be controlled by a rider of the watercraft, means located within the hull for detecting a position of the throttle operator, and means located within the hull for moving said throttle device in response to the detected position of the throttle operator.

11. The small watercraft of claim 10, wherein the means for detecting the position of the throttle operator is located within a substantially waterproof compartment of a case, and the throttle operator is coupled to the case.

12. The small watercraft of claim 10, further comprising communication means between the throttle operator and the means for detecting a position of the throttle operator.

13. The small watercraft of claim 10, further comprising an electronic control unit configured to receive an input signal from the means for detecting the position of the throttle operator, and further configured to output a control signal to the means for moving the throttle device.

14. A throttle control relay assembly for a watercraft having an internal combustion engine, the engine having an air control device for regulating intake air into the engine, a throttle lever configured to be manually operated by a rider of the watercraft, the throttle control relay assembly comprising a throttle lever position sensor configured to detect the position of the throttle lever and further configured to output a data signal corresponding with the signal received from the throttle lever to an electronic controller, an actuator configured to receive a control signal from the electronic controller and having a mechanical output configured to adjust the air control device in response to the control signal from the electronic controller, one or more a watertight cases configured to house the throttle lever position sensor and the actuator.

15. The throttle control relay assembly of claim 14, wherein the throttle lever position sensor is located within a first case and the actuator is located within a second case.

16. The throttle control relay assembly of claim 14, wherein the actuator is mounted adjacent the air control device and is mechanically coupled thereto.

17. The throttle control relay assembly of claim 14, wherein the throttle lever position sensor and the actuator are located within a single case.

18. A power output request device for a watercraft having a hull, an internal combustion engine disposed within the hull, the engine including an air induction system configured to guide air to the engine and which includes an air regulating device to regulate an amount of air supplied to the engine, a steering mechanism including a handlebar assembly coupled to the hull, a power output request device comprising an operator located outside the hull and arranged to be controlled by a rider of the watercraft, an operator position sensor that is configured to detect the position of the operator and to output a request signal that is indicative of the detected position of the operator, an electronic controller in communication with the operator position sensor and configured to receive the request signal and being further configured to output a control signal in response to the request signal, an actuator communicating with the controller and being coupled to the air regulating device, the actuator being adapted to adjust the air regulating device in response to the control signal from the controller, the operator position sensor and the actuator being disposed within the hull.

19. The power output request device of claim 18, further comprising one or more substantially watertight cases configured to contain the operator position sensor and the actuator.

20. The power output request device of claim 18, wherein the operator position sensor is mounted remotely from the operator and remotely from the actuator.